Reinforcing wrap for plastic pipe

ABSTRACT

The combination of a flexible pipe, e.g. plastic, and a reinforcing member mounted around the pipe to strengthen the pipe and to enhance its ability to resist deformation under load. In one embodiment the reinforcing member includes a flexible perforated plastic netting containing an aggregation of lightweight elements such as expanded polystyrene beads capable of wrapping around the pipe, preferably in helical fashion along the length of the pipe. In another embodiment, a number of members are mounted on the pipe in longitudinally extending fashion. In all embodiments, the beads provide drainage around the pipe when it is placed in a trench and obviate the need for gravel normally used in conventional systems.

BACKGROUND OF THE INVENTION

This invention relates generally to large diameter flexible pipe forexample, plastic pipe, used in underground drainage systems and moreparticularly to a pipe having a reinforcing and strengtheningpreassembled drainage line member containing lightweight aggregateplaced on the outside of the pipe to prevent deformation of the pipeunder load and to resist deflection and provide impact resistance duringshipping and handling of the pipe and placement of the pipe into atrench. Normally gravel is placed around the pipe in the trench. Thelightweight aggregate replaces the gravel and enhances drainage aroundthe pipe while providing structural support thereto.

In recent years thin walled, cylindrical plastic pipe constructed ofhigh density polyethylene (HDPE) has been successfully substituted forprior concrete and metal pipe in constructing drainage systems forculverts, cross drains, storm sewers, land fills, and other public andprivate construction. The diameter of the larger pipes range from about12 inches to 60 inches and are manufactured in about 20 foot lengths.Depending upon the application the pipes may be corrugated bothinternally and externally, corrugated externally with a smooth interiorsurface or provided with both smooth interior and exterior surfaces. Thedepth at which these pipes can be buried is from about 12 inch soilcover to as much as 60 foot soil cover.

These large diameter plastic pipes are subjected to various forcesduring transit from a manufacturing facility or a warehouse to a jobsite and while the pipe is being handled at the job site which tend todistort the pipe from its normal circular cross section. Although thepipe is reasonably rigid the forces may tend to flatten, bend or dentthe pipe. Similarly, once the pipe is installed in the undergroundtrench and the pipe is then covered with the backfill material, theweight of that material may deform the pipe from its normal circularcross section to an out of round condition. In addition, once in placeand covered by gravel and fill, vehicles driving over the pipe, e.g.when the pipe is buried under a road, subject the pipe to substantialloads which tend to deform the pipe.

It would be advantageous to provide such large diameter flexible plasticpipe with a system which alleviates those deflection and deformationproblems while facilitating drainage around the pipe and the inventionas described hereinbelow was developed for that purpose.

SUMMARY OF THE INVENTION

Accordingly the primary object of this invention is to provide a simple,inexpensive reinforcing and drainage system which helps maintain thestructural integrity of a large diameter flexible pipe, resistsdeflection and deformation of the pipe under load and replaces thegravel to provide for drainage around the pipe.

This object is accomplished by providing a reinforcing system comprisingat least one preassembled drainage line member which includes an outerflexible perforated sleeve member, e.g. tubular nylon netting or mesh,filled with loose aggregate in the form of lightweight materials, forexample, a plurality of crush resistant expanded polystyrene (EPS) beadstightly bound within the net, the member being secured on the outsidesurface of the pipe to strengthen the pipe and to provide drainagearound the pipe when it is placed in a trench. A thin walled flexibleplastic conduit may be provided within the member, with the lightweightmaterials surrounding the conduit and being bound thereby by the plasticnetting.

Further objects and advantages of the invention will become apparentfrom reading the following detailed description of the invention whereinreference is made to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a generally perspective view illustrating a first embodimentof the invention in which a reinforcing member is wrapped helicallyalong the length of a large diameter pipe to strengthen the pipe;

FIG. 1 a is a schematic illustration of the embodiment of FIG. 1;

FIG. 2 is a perspective view of one form of the reinforcing membersurrounding the pipe in FIG. 1;

FIG. 3 is a perspective view of another form of the reinforcing member;

FIG. 4 is a generally perspective view of a second embodiment of theinvention in which reinforcing members extend longitudinally on theoutside surface of a pipe.

DETAILED DESCRIPTION OF THE INVENTION

As illustrated in FIG. 1 and FIG. 1 a, the first embodiment of theinvention includes a large diameter plastic pipe 10 constructed forexample from HDPE material having a predetermined length, for exampleabout 20 feet, and a reinforcing flexible preassembled drainage linemember 12 tightly helically wound around the outside of pipe 10 from endto end of the pipe to strengthen the pipe and to enhance the ability ofthe pipe to resist deflection and deformation under load.

Flexible reinforcing member 12 may be constructed as illustrated in FIG.2 and includes a central flexible corrugated conduit 14 surrounded by aplurality of lightweight plastic aggregate 16 held in place by asurrounding plastic net or mesh 18 and suitably tied at its end toconduit 14. Member 12 can be manufactured to any desired length toaccommodate any length and diameter of pipe 10.

Alternative member 12 a illustrated in FIG. 3 is essentially identicalto member 12 in FIG. 2 except that conduit 14 has been omitted and eachend of net 18 is suitably tied by a fastener 20 to hold the aggregate 16within. The outer diameter of members 12 and 12 a can vary, e.g. between3 inches and 36 inches depending on the diameter of the pipe 10 whichcan be as large as 6 feet or more.

The reinforcing aggregate units illustrated in FIGS. 2 and 3 are thesame as those illustrated in FIGS. 2 and 3 of U.S. Pat. No. 5,015,123which is owned by the same assignee of this invention. Those members canbe manufactured by the method and apparatus described in the '123 patentor preferably by the method and apparatus illustrated in U.S. Pat. No.6,173,483 which is also owned by the assignee of this application. Thedisclosures of the '123 patent and the '483 patent are incorporatedherein by reference in their entirety.

The aggregate 16 are discrete water impervious, water resistant,lightweight plastic elements, preferably expanded polystyrene (EPS)beads of the type which are illustrated in U.S. Pat. No. 6,467,996 whichis also owned by the assignee of this application. Beads 16 are firmlybound within net 18 but yet member 12 is flexible enough so that it maybe tightly wrapped around pipe 10 in helical fashion, preferably withadjacent coils abutting each other. Each end of member 12 may include agenerally cylindrical coil 13 at an end of pipe 10. Member 12 can besuitably fastened on pipe 10 e.g. by straps 15.

As mentioned above, the reinforcing wrap member 12 which is woundtightly around pipe 10 strengthens the pipe and enhances its ability toresist deflection, for example, bending, denting, or flattening of thepipe during handling and transportation and deformation under load whenit is placed into the trench where it is subjected to the load of thebackfill material which is placed on top thereof and forces caused byvehicles passing thereover. In addition, during transportation wherein anumber of pipes are normally placed side by side and on top of eachother on a flat bed, the reinforcing coil member 12 minimizes andcushions any impact between adjacent pipes 10 and thereby prevents anyindentation or marring or other damage to the outside surface of thepipes and helps maintain the structural of integrity of the pipes.

The reinforcing aggregate members 12 are very light in weight, easy tohandle, and add very little cost to the pipe itself while substantiallyincreasing the strength of the pipe. In addition, when pipe 10 andmember 12 attached thereon are placed in a trench, the EPS aggregatebeads 16 provide drainage around the pipe and structurally support thepipe in use. Beads 16 replace gravel which has been used in priorconventional installations. As a result the invention reducessubstantial labor and material costs in constructing drainage systems.

The member 12 may be quickly and easily attached to a pipe 10 followingthe manufacturing of the pipe by simply first attaching one end ofmember 12 to one end of pipe 10, slowly rotating pipe 10 while movingthe remainder of the wrap linearly along the rotating pipe so as to windthe wrap in helical fashion around the pipe, and then finally attachingthe other end of the wrap 17 around the other end of the pipe. Althoughit is preferable that adjacent coils abut each other, the pitch betweenadjacent coils of the wrap 12 can be varied by varying either the speedof rotation of pipe 10 or the speed of linear travel of the wrap alongthe pipe, or both.

Thus, it is clear that the invention of FIG. 1 accomplishes theobjectives set forth initially hereinabove and provides a simple,inexpensive reinforcing and strengthening system for large diameterplastic pipes. While the reinforcing system is illustrated asconstituting the helical wrap member 12, in some applications the systemmay include a plurality of separate cylindrical wrap members spacedalong the length of pipe 10.

The second embodiment 25 of the invention illustrated in FIG. 4 includesa plurality of members 12 or 12 a secured circumferentially around theoutside of the pipe, each member extending longitudinally from one endof the pipe to the other. The members are secured to pipe 10 by straps30 which wrap circumferentially around the members and the pipe.

As with the first embodiment of FIG. 1, the longitudinally extendingmembers 12 or 12 a of embodiment 25 strengthen the pipe. When theassembly is placed in a trench, the members containing beads 16 providedrainage around the pipe, replacing the gravel and thereby reducinglabor and material costs.

The longitudinally extending members 12 in FIG. 4 may be selectivelypositioned around the circumference of pipe 10 to strengthen a weak areain a pipe installation. For example, when two pipes are placed side byside in a trench in abutting relationship, an open area or haunch 19formed below the line of contact of the pipes, the diverging side wallsof the bottom of the pipes, and the bottom of trench. This open area mayweaken the pipe assembly which may deflect and deform under load. Toavoid this, members 12 may be strategically positioned on one or bothpipes to fill that open area and thereby provide full support for thepipes.

The invention may be embodied in other specific forms without departingfrom the spirit or essential characteristics thereof The presentembodiments are therefore to be considered in all respects asillustrative and not restrictive, the scope of the invention beingindicated by the appended claims rather than by the foregoingdescription and all changes which come within the meaning and range ofequivalency of the claims are therefore intended to be embraced therein.

1-19. (canceled)
 20. A pipe drainage combination, comprising: a pipe;and at least one flexible water-permeable tubular sleeve membercontaining an aggregation of lightweight elements, wherein the at leastone flexible water-permeable tubular sleeve member has a peripheralportion in direct contact with a peripheral portion of the pipe.
 21. Thepipe drainage combination according to claim 20, wherein the at leastone flexible water-permeable tubular sleeve member is substantiallyparallel to the pipe.
 22. The pipe drainage combination according toclaim 21, further comprising a first binding member that secures the atleast one flexible water-permeable tubular sleeve member to the pipe.23. The pipe drainage combination according to claim 22, wherein thefirst binding member comprises one of a strap, a netting, and awater-permeable plastic wrap on the exterior of the pipe drainagecombination.
 24. The pipe drainage combination according the claim 23,further comprising a second binding member, wherein the second bindingmember comprises at least one of a strap, a netting, and awater-permeable plastic wrap on the exterior of the pipe drainagecombination.
 25. The pipe drainage combination according to claim 24,wherein at least one of the first and second binding members areconfigured to be removable upon placement of the pipe drainagecombination in a trench.
 26. The pipe drainage combination according toclaim 25, wherein the pipe is a flexible pipe.
 27. The pipe drainagecombination according to claim 26, wherein the pipe is made from aplastic material.
 28. The pipe drainage combination according to claim20, further comprising a first binding member that secures the at leastone flexible water-permeable tubular sleeve member to the pipe whereinthe first binding member comprises one of a strap, a netting, and awater-permeable plastic wrap on the exterior of the pipe drainagecombination.
 29. A pipe drainage combination, comprising: a plurality ofpipes; and a plurality of water-permeable flexible water-permeabletubular sleeve members, each water-permeable flexible water-permeabletubular sleeve member containing an aggregation of lightweight elements,wherein each water-permeable tubular sleeve member directly contacts atleast one of the plurality of pipes.
 30. The pipe drainage combinationaccording to claim 29, wherein the plurality of flexible water-permeabletubular sleeve members are substantially parallel to the plurality ofpipes.
 31. The pipe drainage combination according to claim 29, furthercomprising a first binding member configured to secure the plurality offlexible water-permeable tubular sleeve member to the pipe.
 32. The pipedrainage combination according to claim 31, wherein the first bindingmember comprises at least one of a strap, a netting, and awater-permeable plastic wrap on the exterior of the pipe drainagecombination.
 33. The pipe drainage combination according to claim 32,further comprising a second binding member wherein the second bindingmember comprises at least one of a strap, a netting, and awater-permeable plastic wrap on the exterior of the pipe drainagecombination.
 34. The pipe drainage combination according to claim 31,wherein at least one of the first and second binding members areconfigured to be removable upon placement of the pipe drainagecombination in a trench.
 35. The pipe drainage combination according toclaim 34, wherein the pipe is a flexible, perforated pipe.
 36. The pipedrainage combination according to claim 35, wherein the aggregation oflightweight elements is comprised of expanded polystyrene beads.
 37. Thepipe drainage combination of claim 29, wherein the plurality of flexiblewater-permeable tubular sleeve members each comprises a tubular sleeveof netting, closed at each end thereof, the aggregation of lightweightelements being contained entirely within the sleeve of netting, andwherein the aggregation of lightweight elements is comprised of expandedpolystyrene beads.
 38. The pipe drainage combination of claim 20,wherein the plurality of flexible water-permeable tubular sleeve memberseach comprises a tubular sleeve of netting, closed at each end thereof,the aggregation of lightweight elements being contained entirely withinthe sleeve of netting, and wherein the aggregation of lightweightelements is comprised of expanded polystyrene beads.
 39. The pipedrainage combination according to claim 21, further comprising a meansfor binding the at least one flexible water-permeable tubular sleevemember to the pipe.
 40. The pipe drainage combination according to claim29, further comprising a means for binding the at least one flexiblewater-permeable tubular sleeve member to the pipe.